Device for connecting electrical conductors

ABSTRACT

A device for connecting electrical conductors such as flat-band lines, printed circuits or the like, in which pressure media are provided to increase contact reliability, and after mounting thereof, said media ensure that the contact areas of at least two electrical conductors are plastically deformed. The best possible contact area is created by the plastic deformation.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a device for connecting electrical conductors. More particularly, the present invention relates to a device for connecting electrical conductors such as flat-band lines, printed circuits, conducting foils or the like.

[0003] 2. Description of the Related Technology

[0004] An exemplary prior art device for connecting flat-band lines is described in DE 198 32 011 A1. In this device, the flat-band line has a connecting area that is provided in a detachable connection. An insulating housing, which has spring means for applying the necessary contact forces, is associated with the connecting area. Means are associated with the individual strip conductors of the flat-band line in such a way that the flat-band lines with their contact areas (which are created by stripping insulation) come to lie directly on the associated counter-contact areas of the counterpart to be bonded under the spring action of the spring means. In this configuration, it is essential that at least one contact curvature be pushed out and raised directly from the flat-band line (with a plastically finish-formed contour present for each contact area), whereby after bonding, the back side of the raised contact curvatures that faces away from the counterpart is loaded directly by a spring means. That is, after bonding, the surface of the contact curvature rests, under spring action, on the connecting area of the counterpart. In the device, the counterpart itself is also a flat-band line.

[0005] A connection (bonding) of flat-band lines that is created in this way has proven its value per se. One drawback, however, is that the contact is immediately lost if spring action is no longer present. This is a common occurrence, for example as in the device disclosed in DE 198 32 011 A1, it will be appreciated that the spring means are designed as leaf springs which are known to break under harsh environmental conditions.

[0006] Another drawback in these types of devices is that the contact curvature comes to lie only tangentially to the connecting area that is involved. As a result, it is practically impossible to produce a high-load electrical connection through which high currents can flow because the contact surface is too small.

[0007] In addition, another drawback resides in the fact that before bonding, the contact curvatures must be introduced into the flat-band line by means of an additional operating step. As will be appreciated, a high precision in the positioning of the contact curvatures is necessary. Typically, the contact curvatures must be introduced at precisely the point in the flat-band line in which the spring means can later engage. As will be appreciated, if the spring means is not located exactly in the area in which a contact curvature in the flat-band line is present, inadequate forces or forces outside of the contact area will exist, and accordingly, reliable bonding is not possible.

SUMMARY OF THE INVENTION

[0008] One object of the present invention is to avoid the above-mentioned and other drawbacks. Another object of the present invention is to provide a device for connecting electrical conductors which can be produced simply and economically, while also resulting in a device which has reliable bonding.

[0009] These and other objects of the present invention may be realized by a device comprising a first electrical conductor having a contact area (which may comprise an area stripped of insulation), a second electrical conductor having a contact area adjacent to the first electrical conductor, and pressure media which exerts force on the contact area of the first electrical conductor sufficient to connect the electrical conductors.

[0010] According to one aspect of the invention, the pressure media exert their force on the contact areas of the electrical conductors in such a way that after the connection, the contact areas of the two electrical conductors are plastically deformed.

[0011] In accordance with this aspect of the invention, one of the advantages of the present invention lies in the fact that an additional step for the production of contact curvatures can be avoided since the contact curvature is produced only owing to the exertion of pressure of the pressure media on the contact areas that are involved. Thus, any electrical conductors such as flat-band lines, printed circuits or flat-band foils can be used that must not be touched beforehand except for stripping insulation. That is, the contact areas that are involved are deformed plastically in the area in which the pressure media are found.

[0012] In accordance with another aspect of the invention, buffers can be present that can be deformed elastically and introduce an additional contact force after the connection, especially over the service life of the connection.

[0013] The plastic deformation of the electrical conductors that are involved in the contact area has, moreover, the advantage that the largest possible surface of the contact areas to be bonded comes to rest so that high contact reliability is provided. By the large-area bonding, it is possible at the same time to transmit high currents with comparatively thin or flat electrical lines. Since the pressure media do not necessarily have to be (but can be) absolutely loaded with spring force, the risk of a spring break, from which a contact interruption would result, is also avoided.

[0014] Another advantage of the present invention is based on the plastic deformation, wherein according to this aspect, oxide layers break open and thus the bonding is further improved.

[0015] In accordance with another aspect of the invention, the pressure media and the contact areas are arranged in a housing, preferably a multipart housing. By the use of a housing, the pressure media, as well as the electrical lines that are involved, can be positionally fixed, whereby the contact areas are also protected from mechanical damage. In addition, the housing can be used to position the entire arrangement at a desired point.

[0016] In accordance with another object of the present invention, the contact areas can be closed tightly by using a seal. As a result, ambient or environmental influences (such as, for example, moisture, pollution by electrically conducting particles, etc.) cannot act on the contact areas, so that corrosion, short circuits, etc., can be avoided.

[0017] The housing preferably comprises two halves, whereby the inside of the housing is tightly sealed by a seal that is lodged between two housing halves. This seal can be inserted between the housing halves or pre-mounted (for example molded-on) on the outside contours of one housing half. This seal mainly has the purpose of preventing the occurrence of a short circuit between contact areas. As will be appreciated, it is ensured by the seal that each contact area, several contact areas, or all contact areas are protected from outside influences (such as moisture, electrically conducting particles, or the like), so that no short circuits are produced.

[0018] The seal can comprise all contact areas, can be arranged around a contact area, or be arranged between two strip conductors.

[0019] In accordance with another aspect of the invention, at least a portion of the pressure medium is electrically conductive. As will be appreciated, this has the advantage that the pressure media can assume two different functions. On the one hand, after the connecting and bonding of the electrical conductors, they produce their plastic deformation. On the other hand, they can be used for further bonding since they are found in a contact area of an electrical conductor. Thus, for example, the pressure media can be designed as a contact sleeve or contact pin. Additional electrical conductors, connectors, electrical components (such as, for example, bridges) or electronic components or even electronic modules can be connected to this sleeve or to the pin.

[0020] In accordance with an aspect of the invention, several pressure media that are arranged beside one another are not only designed for bonding and plastic deformation, but also are designed as multipolar connectors or as multipolar sleeves, by which a signal or voltage transmission can be carried out.

[0021] According to yet another aspect of the invention, the pressure media are loaded with spring force. This has the additional advantage that the large-surface contact areas that lie on top of one another, are plastically deformed and thus adapted or loaded by an additional force after bonding so that the bonding is still reliable. The force can be produced by any suitable means, for example by use of a spring or alternatively by use of an elastically deformable intermediate layer.

[0022] In accordance with another aspect of the invention, the electrical conductors lie plane-parallel over one another on a base disposed at least in the contact area, whereby the plastic deformation takes place in the contact area and the support area of the base. As a result, the electrical conductors are placed over one another plane-parallel in a simple way. Then the pressure media are mounted so that the contact areas of at least two electrical conductors are plastically deformed by the mounting of the pressure media. This plastic deformation can be carried out in such a way that the base may or may not be plastically deformed. If the base is not deformed, it must have a material property that withstands the exertion of force of the pressure media. In such a case, it is preferable that the pressure media are also at least partially plastically deformed in the exertion of force. Alternatively, the base can consist of a material that is also deformed with the exertion of force and plastic deformation of the contact areas. If the material of the base does not consist of a plastically deformable material, it is also conceivable to introduce a plastically deformable seating between the base and at least one electrical conductor, whereby said seating is plastically deformed after the exertion of force by the pressure media. Owing to its elasticity, this seating or other suitable medium then preserves the connection over the service life of the device.

[0023] In accordance with another aspect of the invention, the electrical conductors lie plane-parallel over one another between at least two pressure media disposed in at least the contact area, whereby the plastic deformation is carried out in the contact areas. In each case, two pressure media are prefereably disposed opposite one another in the contact area, so that the intervening electrical conductors can be plastically deformed. Here, of course, attention must be paid that the exertion of force of the opposite pressure media is not so high that the latter would penetrate the contact areas of the electrical conductors that are involved so that a bonding would be prevented.

BRIEF DESCRIPTION OF THE FIGURES

[0024] Various embodiments of the invention, to which the invention is not limited, however, are described below and explained wherein:

[0025]FIGS. 1 and 2 show devices for connecting electrical conductors before mounting according to the invention,

[0026]FIGS. 3 and 4 show devices for connecting electrical conductors after mounting according to the invention,

[0027]FIGS. 5 and 7 show another embodiment of a device for connecting electrical conductors according to the invention,

[0028]FIGS. 8 and 10 show a device for connecting electrical conductors with a connector, and

[0029]FIG. 11 shows a microscope image in section.

DETAILED DESCRIPTION

[0030] In FIG. 1, a sectional drawing through a hardware example for connecting electrical conductors is shown. As depicted, a first flat-band line 1 and a second flat-band line 2, both of which are stripped of insulation, lie plane-parallel over one another in the contact area. As depicted in FIG. 1, there is a plastically deformable seating 3 under first flat-band line 1, and the seating in turn rests on a non-plastically deformable base 4. A housing is 5 is found above base 4, whereby base 4 can be a component of housing 5. Two pressure media 6 are arranged in housing 5, which, when housing 5 moves in the direction of base 4 for the purpose of mounting and then is set, receives two pressure media 6. Two pressure media 6 also penetrate an intermediate layer 7, which is arranged somewhat plane-parallel to base 4.

[0031]FIG. 1 also shows that pressure media 6 may have any suitable configuration. As depicted, pressure media may comprise a contact sleeve 8 or a contact pin 9. As will be appreciated by one of ordinary skill in the art, if pressure media 6 are designed as a contact sleeve 8 or contact pin 9, housing 5 or a part thereof is also designed as a connector or sleeve in a complementary way.

[0032] As an alternative to the embodiment shown in FIG. 1, the pressure media can also consist of a plane-parallel plate and have curvatures in the area of the contact area of two flat-band lines 1 and 2. This plate (or housing 5 and intermediate layer 7) is moved in the direction of base 4 for the purpose of connecting and bonding and sets after bonding has been completed.

[0033]FIG. 2 shows an embodiment similar to FIG. 1 before mounting thereof, whereby here it is shown that reference numeral 10 is a housing upper part that receives pressure media 6, which are designed as contacts. An electronic component 11 is connected between these two contacts (pressure media 6). Instead of an electric component, a bridge or an electronic modulus (i.e., with several electronic components) could also be arranged here.

[0034] In addition, it is shown in FIG. 2 that housing upper part 10 has a circumferential seal 12, whereby seal 12 can also be attached to base 4, the component of the housing. As an alternative to this, it is also conceivable that seal 12 be used between base 4 and housing upper part 10. With seal 12, it is achieved that several contact areas of two flat-band lines 1 and 2 are protected from outside influences.

[0035]FIG. 3 (FIGS. 3A and 3B) shows a for connecting electrical conductors according to the invention after their mounting, whereby the device that is depicted in FIG. 2 is reproduced in a cutout, but after its mounting. It can be seen in FIG. 3A that housing upper part 10 with its pressure medium 6 was moved in the direction of base 4, so that the mushroom-shaped end of pressure medium 6 could exert its force on the contact areas of the first and second flat-band lines 1 and 2 and correspondingly plastically deformed the latter. At the same time, seating 3 was also plastically deformed, whereby base 4 comprises a material that withstands the exerted pressure.

[0036] As can be seen clearly in FIG. 3, two flat-band lines 1 and 2 in their contact areas preferably rest on as large a surface as possible in order to maximize bonding. After this mounting, housing upper part 10 is rigid relative to base 4 before force is exerted on the contact areas (either plastically deformed seating 3 exerts the force or pressure media 6 are loaded with spring force).

[0037] In addition, it can be seen in FIG. 3A that seal 12 does not rest on base 4 in this embodiment. Instead, seal rests on a flat-band line 2. It thus is possible to preserve the sealing action while a flat-band line 2 is simultaneously brought out. This seal 12 can be arranged around the entire device, around contact area groups or around individual contact areas.

[0038]FIG. 3B shows an embodiment similar to FIG. 3A, except that there is no plastically deformable seating 3 having elastic properties (as in FIG. 3A). In this embodiment, base 4 is plastically deformable and preferably has elastic properties. In addition, base 4 can have recesses that are slightly smaller than the form of the corresponding pressure media, whereby the contact areas nestle against the recesses.

[0039]FIG. 4 shows another device for connecting electrical lines after their mounting, whereby it is shown that pressure media 6 cannot assume any electrical function whatsoever, but rather are designed as plane-parallel plates with mushroom-shaped curvatures. As depicted in FIG. 4, the electrical conductors that are to be connected are printed circuits 13 and 14 between which the contact areas of first and second flat-band lines 1 and 2 are found, whereby the latter can be connected with the contact areas of the printed circuits. Also, here, there is an intervening seal 12, which protects the contact areas from environmental influences, between printed circuits 13 and 14.

[0040] In FIGS. 5 to 7, various additional aspects of the invention and alternative embodiments of the device for connecting electrical conductors are depicted.

[0041]FIG. 5 shows a printed circuit 15 having several strip conductors 16 arranged thereon. In this embodiment, the end areas of strip conductors 16 are arranged concentrically around a hole 17 disposed in the printed circuit 15. Alternatively, an oval, parallel or linear arrangement of the end areas is conceivable.

[0042] In FIG. 6, it is shown that at least two such printed circuits 15, as depicted in FIG. 5, lie plane-parallel over one another. For this purpose, individual strip conductors 16 of the printed circuits 15 are facing one another. Two pressure plates 18 are also arranged in a plane-parallel manner to sandwich the printed circuits. Pressure plates 18 are provided with pressure media (here mushroom-shaped projections) concentrically around hole 17 in a manner which corresponds to the points at which strip conductors 16 end.

[0043] Pressure plates 18 also have a non-designated hole in which connecting means 19 can be introduced. For connection, connecting means preferably has a base 4 which comes to lie on a pressure plate 18, and as shown on the left side of FIG. 6, a spring 20 (disk spring) adapted to be superposed and stretched by connecting means 19, which can have, for example, a thread in its interior in which a screw is inserted from the left, which has the effect that the printed circuits 15 and pressure plates 18 are pressed on one another plane-parallel in the direction of base 4.

[0044] By this movement and because of the projections in pressure plate 18, a slightly plastic deformation of printed circuit 15 or end areas of strip conductors 16 is carried out so that the latter nestle against one another, and maximum bonding is provided.

[0045] As is depicted in FIG. 6, still another flat-band line, a two-sided coated printed circuit or an electrical conducting foil can be found between two printed circuits 15, but is not necessarily required.

[0046]FIG. 6 shows that two pressure plates 18 are connected to one another via a flexible strap to ensure that the mushroom-shaped projections of pressure plates 18 are always found in the area of the concentrically arranged ends of strip conductors 16 around hole 17 even during or after the mounting. Such a structure can be produced from, for example, plastic as an injection-molding part. The flexible strap can be removed before or after the mounting.

[0047]FIG. 7 shows a similar arrangement in which flat-band line 1 is connected with two printed circuits 15. Here again, at least one printed circuit 15 has strip conductors 16, which are arranged according to the embodiment of FIG. 5. Contrary to the embodiment depicted in FIG. 6, two pressure plates 18 are not connected to one another via a strap. The mounting of the device for connecting electrical conductors shown in FIG. 7 is carried out, for example, in the following way:

[0048] Mechanical connecting means 19 already has base 4, in which lower pressure plate 18, which also has a hole, is pushed open. Then, printed circuit 15, flat-band line 1 and other printed circuit 15 are pushed open, and upper pressure plate 18 is placed on top of it. Then, spring 20 is also mounted, and the elements that are involved are pressed together by a blind rivet 21 in the direction of base 4. Then, the arrangement that is shown in FIG. 7 can be sealed by a housing by any suitable means. Mechanical connecting means 19 can consist of electrically conducting material or insulating material and optionally be designed for bonding or passing through voltages, passing through signals or for making a mass point.

[0049] Spring 20 can also be replaced or supplemented by an elastically deformable intermediate layer between printed circuits 15.

[0050] In FIGS. 8 to 10, a device for connecting electrical conductors with a connector is shown. While in the preceding embodiments an essential task was to connect together at least two electrical conductors such as flat-band lines or the like, in the embodiment that is shown in FIGS. 8 to 10, the point is either to bond together at least two flat-band lines and to grip at least one flat-band line via a connector or the like or even to grip bonded flat-band lines via the connector. A connector does not absolutely have to be used. A sleeve, an electric bridge or electronic component (e.g., resistor, coil, condenser) or an electronic system (e.g., microprocessor, modulus) can also be used.

[0051] To this end, a printed circuit 22, on which several strip conductors 23 are arranged (here arranged at right angles, in general, however, the arrangement is arbitrary), is shown in FIG. 8. At the ends of each strip conductor 23, a contact point 24 and 25 is present. In the outside areas of printed circuit 22 there are provided holes 26 through which the connecting means can be carried out.

[0052] In FIG. 9, a connector 27 is shown, which in terms of its basic dimensions has approximately the same basic dimension as printed circuit 22. Connector 27 has several contact pins 28, whereby inside connector 27, each contact pin 28 is guided outward via conducting tape 29 and ends in a contact tag 30. Each of contact tags 30 that are guided outward corresponds to the position of respective contact point 24 of printed circuit 22. Connector 27, corresponding to the position of holes 26, also has holes to which reference is not made.

[0053] Printed circuit 22 and connector 27, as they are shown in FIGS. 8 and 9, can be combined with one another in the following way:

[0054] Connector 27 is either mounted plane-parallel on printed circuit 22 and is connected to it by connecting means (such as rivets or the like, which are guided through holes 26), in such a way that contact tags 30, under which connector 27 projects slightly, come to rest under pressure on contact points 24 so that at least one strip conductor 23 is plastically deformed in the area of contact point 24, depending on the arrangement of contact tags 30.

[0055] It is also possible, however, that between printed circuit 22 and connector 27, another flat-band line is placed, which is to be connected with at least one contact point 25. For this purpose, the flat-band line that is placed in between (or else several flat-band lines) is stripped of insulation at the points at which the strip conductor in question is to make contact with contact point 25, whereby at the same time, connector 27 has projections in the form of pressure medium 6 on its underside, so that after the assembly of printed circuit 22 and connector 27 including that placed in between, bonding is done by plastic deformation.

[0056] In FIG. 10, a type of production of a connector 27 is shown, in which connector 27 consists of plastic, and conducting tapes 29 are designed as plastic-encased pressed screens. In addition, it can be clearly seen in FIG. 10 that here contact tag 30 is designed as a curvature, by which the pressure medium is formed for plastic deformation. In the area facing contact tag 30, conducting tape 29 has the contact pin that is pressed into a hole of conducting tape 29, whereby in its end area, conducting tape 29 is run around contact pin 28 into the form shown in FIG. 10, by which contact pin 28 is held securely in its position.

[0057]FIG. 11 shows a microscope image of a device for connecting electrical conductors in section. Flat-band lines, i.e., the electrically conducting part of the flat-band line, are referred to with reference numerals 1 and 2. The latter are arranged on a respective carrier 31 and 32, whereby carrier 31 or 32 can be a thin, flexible plastic carrier. It is also conceivable, however, that carrier 31 and 32 is rigid and thus less plastically deformable, or one carrier is flexible and the other carrier is rigid. After the two flat-band lines are laid one on top of the other on base 4, a high, partially acting pressure is produced by applying pressure medium 6 and producing the pressed connection (such as, for example, by the blind rivet) in the area of pressure medium 6, so that both the flat-band line and the carrier (and optionally base 4) deform plastically. In this case, the pressure in the area of pressure medium 6 is so high that an electrically conducting area of flat-band lines 1 and 2 are pressed together in such a way that it is sealed in the contact area of the latter tightly against air, gas, and against other influences. In correspondingly higher exertion of pressure, even a cold fusing of areas to be bonded electrically results, by which reliable connection is produced in every case.

[0058] Other connecting measures such as soldering or the like are therefore unnecessary, such that the pressure applied alone is sufficient to ensure permanent electrical contact, whereby additional sealing measures relative to the bonding can be dispensed with. Sealing measures with respect to single, several or all contact areas relative to the short-circuit protection can be performed, however. 

What is claimed is:
 1. A device for connecting electrical conductors comprising: a first electrical conductor having a contact area, a second electrical conductor adjacent said first electrical conductor, a pressure media, said pressure media adapted to exert a force on said contact area sufficient to connect said first and second electrical conductors in a plastically deformable manner.
 2. The device of claim 1, wherein said second electrical conductor has a contact area, and said first and second electrical conductors are connected and plastically deformed at their contact areas.
 3. The device of claim 2, wherein said contact areas comprise areas of said electrical conductors stripped of insulation.
 4. The device of claim 1, further comprising a housing which houses said pressure media and said contact area.
 5. The device of claim 4, wherein said housing comprises two housing halves configured to mate in sealing engagement.
 6. The device of claim 5, further comprising a seal adapted to tightly seal said contact area in said housing.
 7. The device of claim 1, wherein at least a portion of said pressure media is electrically conductive.
 8. The device of claim 7, wherein said pressure media comprises a contact sleeve or a contact pin.
 9. The device of claim 1, wherein said pressure media comprises a plane-parallel plate having a mushroom-shaped curvature for contacting said contact area.
 10. The device of claim 1, further comprising a spring, said spring adapted for providing additional force for connecting said first and second electrical conductors.
 11. The device of claim 1, further comprising a base disposed adjacent said second electrical conductor, wherein said base is also deformed when said first and second electrical conductors are connected.
 12. The device of claim 1, further comprising a base having a plastically deformable seating adjacent said second electrical conductor, wherein said plastically deformable seating is also deformed when said first and second electrical conductors are connected.
 13. The device of claim 1, further comprising first and second printed circuits, said first and second printed circuits being disposed on respective sides of said first and second electrical conductors, wherein said first and second electrical conductors comprise flat-band lines and wherein upon contact induced by said pressure media the first and second printed circuits are in electrical contact with respective first and second flat-band lines.
 14. The device of claim 1, further comprising a second pressure media disposed opposite said pressure media, whereby the two pressure media cooperate to connect said first and second electrical conductors.
 15. A device for connecting electrical conductors comprising: a pair of printed circuits facing each other, each of said printed circuits having a face comprising strip conductors having end areas, said end areas being disposed concentrically around an opening defined by each of said printed circuits; a pair of pressure plates sandwiching said printed circuits, each of said pressure plates defining an opening corresponding to the openings in said printed circuits and each plate also having pressure media corresponding to the end areas of said strip conductors; and a connector configured to extend through said openings and force said pressure media to exert deformable contact pressure on said printed circuits.
 16. The device of claim 15, wherein said connector comprises a body having a base on one end and a forcing element disposed on an opposite end, whereby when said body is disposed through said openings the base and forcing element cooperate to apply said deformable contact pressure.
 17. The device of claim 16, wherein said forcing element comprises a disc spring.
 18. The device of claim 16, wherein said body comprises electrically conducting material.
 19. The device of claim 16, wherein said body comprises insulating material.
 20. The device of claim 16, further comprising at least a first flat-band line disposed between said facing printed circuits. 